Battery Pack Thermal Shield for Safe Vent-End Component Layout
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Solution Overview
Problem
Conventional electric vehicle battery packs face limitations in housing electrical components due to the risk of thermal damage from high temperatures and thermal events, which restricts the placement of components near battery venting ends, leading to design constraints and reduced packing efficiency.
Innovation Solution
The implementation of a thermal shield made from a metallic substrate with a thermal-resistant coating, positioned between battery venting ends and electrical components, deflects gases and heat, allowing components to be placed closer to batteries and enabling more compact and efficient battery pack designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrical components are placed closer to battery venting ends to increase component density, then battery pack efficiency improves, but the risk of thermal damage to components increases
Solution Approach 1:
A thermal shield made of heat-resistant material is positioned between the battery venting end and the electrical components. This intermediary barrier deflects thermal events, flames, and vented materials away from the components, allowing them to be placed closer to the battery without increasing thermal damage risk.
Solution Approach 2:
The thermal shield is pre-positioned to intercept and deflect thermal events before they can reach the electrical components. By establishing this protective barrier in advance, the system prevents thermal damage rather than responding to it after occurrence.
2Reliability
If components are placed away from battery venting ends to avoid thermal damage, then component safety improves, but battery pack design flexibility and packing efficiency deteriorate
Solution Approach 1:
The thermal shield serves as a mediator that decouples the spatial relationship between components and battery venting ends. Components can be positioned freely on the shield without direct exposure to thermal events, eliminating the need to locate them far from venting ends while maintaining safety.
3Object-affected harmful factors
If a thermal shield is added to protect electrical components, then component protection from thermal events improves, but battery pack structural complexity increases
Solution Approach 1:
The thermal shield is implemented as a relatively thin, simple structural element that provides effective thermal protection without adding significant complexity to the battery pack design. The shield can be a simple plate or curved surface that deflects thermal events.
Solution Approach 2:
The thermal shield serves multiple functions: it deflects thermal events, provides a mounting surface for electrical components, and can be integrated with existing battery pack structural elements. This multi-functionality reduces the need for additional separate protective structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The thermal shield effectively protects electrical components from thermal damage, enabling their placement over battery venting ends, thereby increasing the component density and efficiency within the battery pack while preventing damage from heat and flammable emissions.
Implementation Method 1
The thermal shield deflects gases and other materials away from the components
Implementation Method 2
The substrate may optionally have a thermal-resistant coating, such as flame-resistant coatings, formed on the side facing the batteries. This coating may be of any material that increases the thermal resistance of the thermal shield.
Implementation Method 3
The thermal shield acts as a physical barrier isolating and preventing gases and particulate matter expelled from the battery when undergoing a thermal event from damaging the components thereon
Data Source
AI summary
An electric vehicle battery pack with a thermal shield that protects internal components from, for example, battery ventilation, and in particular allows battery pack electrical components to be placed above venting ends of batteries. The thermal shield is positioned above the venting ends of one or more batteries, and various battery pack electrical components may be placed above the thermal shield. Gases and particulate matter from battery venting are thus intercepted and deflected by the thermal shield, instead of damaging battery pack electrical components. In this manner, various battery pack electrical components may be placed above battery venting ends without risk of damage. This allows for a more compact and versatile arrangement of battery pack components.